Production of branched-chain paraffin hydrocarbons



Dec. 16, 1941.

E. 1 DouvlLLE TAL' PRODUCTION 0F BRANCHED-CHAIPARAFIN HYDROCARBONS Filed Dec. 14, 193e 2 Sheets-Sheet 1 MM. wuv

Dw- 16, 1941- E. L. DouvlLLE E-rAL v2,266,012

PRODUCTION OF BRANCHED-CHAIN PARAFFIN HYDROCARBONS 2 Sheets-Sheet 2 Filed Dec. 14, 1938 l Patented Dec. 16, 1941 nocAnBoNs Edmond L. dOuville and Bernard L. Evering,

Chicago, Ill., assignors to Standard Oil Company, Chicago, Ill., a corporation of Indiana Application December 14, 193s, serial No. 245,570

(ci. 26o-m6) 14 Claims.

,This invention relates to the production of branched-chain paraiiin hydrocarbons from nor-- mally liquid hydrocarbons and more particularly to the conversion of normally liquid saturated hydrocarbons and mixtures .thereof containing a large proportion of straight-chain paraflins into products consisting predominantlyv of branchedchain parafn hydrocarbons.

In the operation of many petroleum refineries considerable quantities of straight run naphthas are available whichA contain suchlarge'proportions of straight-chain parailln hydrocarbons that they are virtually useless for blending into motor fuel because of their extremely low antiknock values, which may range for example from about 40 to below zero octane number. On the other hand branched-chain parailn hydrocarbons are quite valuable, those having from to 12 carbon atoms per molecule being very desirable constituents of motor fuels because of' their high antiknock values and freedom from gumforming tendencies. Mixtures of these hydrocarbons which contain from 5 to 7 carbon atoms per molecule are particularly suited for use as constituents of airplane fuels dueto their relativelyhigh heat content per unit weight of fuel, and such mixtures can be readily and economically/produced by means of our invention. In'

addition the normally liquid branched-chain parafns as well as isobutane, which can also be one of our products, are very useful as startingmaterials in the manufacture of. many chemical products. By carrying out our invention according to certain modifications thereof, an important product is isobutane, and this -is a key material for the preparation of hydrocarbon products which have a premium value. For example, the isobutane can be alkylated with olens such as propylene, the butylenes, or gases containing them in .the presence of suitable catalysts such as sulfuric acidto produce higher isoparailins of excellent antiknock and stability characteristics,

or it can be dehydrogenated to isobutylene over a catalyst such as chromic oxide gel ormagnesium chromite and this isobutylene polymerized` by known means to resins, lubricating oils or di-isobutylene. The latter compound is of course easily converted to so-called iso-octane by hydrogenation, and the dehydrogenation step is a convenient source of hydrogen 'for the hydrogenation o fthe di-isobutylene, or this hydrogen can be used in carrying out the conversion of straight-chain to branched-chain paraflin hydrocarbons according to our invention.

Other investigators have proposed methods of. producing iso-butane and higher saturated branched-chain hydrocarbons from straightchain parafdns using aluminum chloride as the catalyst, but these methods result in such low yields of the desired products based on the catalyst consumed that they are much too expensive for practical use. Aluminum chloride very readilyforms a complex with the hydrocarbons present, and the rapid degradation of this complex to an inactive sludge has been a major factor in the low yields obtained by prior methods.

We have found that excellentl yields of branched-chain saturated hydrocarbons can be obtained from normally liquid parailln hydrocarbons by subjecting them at relatively high temperatures' and pressures to the action of a catalyst of. the aluminum chloride type in the presence of an activator, hydrogen and lightl paraiilnic gas. The nature and amount of this paraiiinic gas-used depends to a great extent 'upon the products desired and this relationship will subsequently be discussed in detail.

It is an object of our invention to provide a process for the production of branched-chain saturated hydrocarbons with highl yieldsper unit of catalyst consumed from normally liquid saturated hydrocarbons such as predominantly parafnaphthas. Another object is tolprovidef'a process whereby naphthas of low antiknock values are converted into saturated branched-chain paraflin hydrocarbons of high stability, high knock ratingand of volatility suitable for use as airplane fuels. Still another object is to provide a method of preparing a product consisting substantially of isobutane from liquid straight-chain parain hydrocarbons and` mixtures thereof. Other objects, advantages and uses of our invention will appearfrom the following detailed description read in conjunction with the drawings l a part of this specification and in which form which:

Figure 1 shows in a schematic manner an ap- Y paratus suitable for carrying out our invention in certain of its modifications; and

lrange from about 500 to about `6000 pounds per square inch, and with the addition of an activator, free hydrogen anda paraflinic gas consisting predominantly of propane with or Without one or both of the butanes.

The feed stock to our process can b'e a relatively pure normally liquid straight-chain paraffin hydrocarbon such as normal heptane, but generally predominantly parafnic straight-run naphthas such as those from Mt. Pleasant, Pennsylvania, or Mid-Continent crude oil are preferred since they are much more readily available. It is very important that the feed stock be almost free from aromatic hydrocarbons since they have been found to reduce the activity of the catalyst to a very marked degree and consequently seriously limit the amount of conversion obtained per unit weight of catalyst. Our preferred feed stock therefore contains less than 5% and preferably 0.5-1.0% or less of aromatic hydrocarbons. In many cases a preliminary solvent extraction step is necessary or desirable to reduce the aromatic content of the feed to a value suiciently low to minimize interference with the catalyst activity.

Our invention is not applicable to cracked naphthas because of their large content of aromatics and oleiins. A relatively small amount of the latter can be tolerated in the reaction, but they are preferably substantially absent since they tend to reduce the catalyst activity, althoughl not as markedly as do the aromatics. Naphthenic or cycloparaflinic hydrocarbons on the other hand are not injurious to catalyst life but react with great facility to form isomers, cyclohexane for example being converted to methyl cyclopentane almost quantitatively. Since the conversion of straight-chain paraflin hydrocarbons of low value into the more useful branchedchain parailin hydrocarbons is the desired reaction, it is preferred to use a feed stock containing a relatively small proportion of naphthenes. l

'I'he liquid feed to our process can have a wide boiling range, a relatively narrow one, or, as indicated above, it can be a substantially pure normal parain hydrocarbon. In general. the feed stock will boil within the range from about 100 F. to about 500 F. Under some conditions, however, it is advantageous to use a feedv boiling action, retains its activity for a 'considerable period of time and is useful for further conversion of straight-chain parallins, especially at relatively high temperatures. In practicing our invention only small amounts of catalyst per unit weight of charge, e. g. less than 5%, are required and we prefer to use about 0.5-2.0% by weight. As activator we can use a hydrogen halide or any compound which in the presence of the catalyst yields a hydrogen halide under the reaction conditions, preferably in an amount suilicient to supply about 0.03 to 3.0 per cent by weight of hydrogen halide based on the charge. Our preferred promoter is hydrogen chloride, but hydrogen bromide, carbon tetrachloride, the alkyl halides such as methyl chloride or bromide, ethyl chloride or bromide, etc. can be used. In general the chlorinated and brominated hydrocarbons, particularly the more volatile ones, are suitable.

An important feature of our invention is the carrying 'out of the reaction at the relatively high temperatures and pressures specified above, namely 300 F. to 500 F. or preferably 350 F. to 475 F. and 500 to V6000 pounds per square inch. Under these conditions much higher conversions per weight of catalyst are obtained in appreciably reduced reaction times, and partially spent catalyst or complex which has little activity at lower temperatures is effective in converting further quantities of straight-chain into branched-chain tained but this is an indication of drastic overabove about 235 F. and containing hydrocarbons having 8 or more carbon atoms per molecule for the reason that this facilitates the separation of unreacted feed from the more volatile liquid present, and limiting the'percent of the latter through the Vreaction zone, so that it is advantageous to add it rather than isobutane whenever it is available. Methane'and ethane are without eiect in preventing the degradation of liquid parailns to gases and their presence in the reaction zone is generally undesirable since they act as diluents and complicate the handling of the reaction products, but minor quantities can, of course, be present.

As hereinabove stated we greatly prefer to of catalyst.

In some casesit may be desirable to obtain a product containing a large proportion of isobutane from the liquid feed and this can be done by reducing the quantity of butanes charged to the reaction step or, as mentioned above, eliminating their use entirely while continuing to add propane. Preferably, the reaction in this case is carried out at a higher conversion per pass, e.l g.

80-85%, by using more catalyst, longer contact time, etc. Furthermore, the yield of isobutane can be raised an additional amount by recycling the heavier products, but generally these products are of such value that their further treatment is economically undesirable.

` It is apparent that the process of our invention can be carried out either batch-wise or continuously, although we prefer continuous operation, and that certainportions of the apparatus must be constructed of corrosion-resistant materials to prevent rapid deteriora-tion thereof from the active halogen compoundsv present. We have found that iron-compound impurities should be eliminated as far as possible from the reaction zone. For example, ferric oxide definitely lowers the amount of conversion. We have also found that the use of iron and carbon steel reaction vessels greatly decreases the amount of conversion obtainable, so that it is preferred that the reaction vessels be constructed of or lined with non-ferrous materials such as glass, ceramic substances, aluminum, etc., or corrosion-resistant alloys such as stainless steel. In the case of stainless steel containing 18% chromium and 8% nickel, it was found that a `somewhat greater amount of activator was necessary in order to obtain yields of products comparable with those obtained in glass apparatus, but the cost-of the additional activator may be balanced against the greater durability of stainless steel equipment.

Our invention will now be described in more detail in connection with the single stage apparatus shown in Figure l. Thenormally liquid feed is introduced into the system by means of pump I8 and line II and thence into the lower portion of the reaction vessel I2 which is shown as a jacketed pressure vessel equipped with a stirring device I3 so that the reaction materials are thoroughly contacted. The desired reaction temperature is maintained by passing a suitable gaseous or liquid heating agent through the :lacket I4 of reaction vessel I2 by means of inlet I5 and outlet I6. Light paramnic gas consisting predominantly of propane and -at least one of the butanes, catalyst slurry and activator are intinuously withdrawn from the upper portion of vessel I2 through line 25 and passes either through valve 28 and cooler 21 or through bypass valve 28 or partly through each valve into separator 29. The products consist of a catalyst complex which settles out in the lower portion of separator 29, and an upper layer consisting of a mixture of hydrocarbons containing branchedchain paramns having from 4 to '1v or more carbon atoms per molecule,- unreacted feed stock, unreacted light para'in gases yand dissolved hydrogen. The catalyst complex is continuously withdrawn from separator 29 through line 30 and either recycled to line ZI through valve 3l, line 32 and pump 33 or withdrawn from the system through valve 34 and line 35, or under some conditions a portion of the complex may be continuously Withdrawn from the system and the remainder recycled. The substantially spent complex can, of course, be regenerated or the aluduced into the system'through pump I8.

The upper layer is removed from separator 29 Athrough line 36 and passed through valve 31 into fractionating tower 38, valve 39 in line 40 being closed. Valve 31 is preferably of the pressuretroduced into line II and mixed with the feed well-known in the art can be substituted therefor.

A portion of the entire reaction mixture is oo nreducing type adjusted to the desired fractionating pressure. Fractionating tower 38 is of a conventional type provided with two sidestream outlets 4I and I42 and is operated so that the bottoms therefrom contain undesirably heavy hydrocarbons, the normally liquid hydrocarbons falling within a desired boilingvrange are withdrawn through outlets 4I and 42 and gases having less than 5 carbon atoms per molecule are withdrawn overhead through line 43. The heavy liquids collecting at the bottom of fractionator 38 are withdrawn through `line 44 and are preferably recycled to line II for further treatment through line 45, pump 46, and line 41. Under some -conditions it may be desirable to withdraw a portion of these heavy liquids vfrom the system and this can bie done through valve 48 and line 49. When using a feed stock boiling above 235 F., fractionating tower 38 can be so operated that the products and unreacted feed boiling in this range are not vaporized but collect in the tower bottomand are recycled in this manner, while the lower boiling liquid products are recovered as sidestreams through lines 4I and 42. Alternatively the conditions in fractionating tower 38 can be regulated so that the liquid products boiling in the motor fuel range, e. g. about 100- v 400 F., are obtained as side streamswhile the heavier fraction is, recycled.

The sidestreams consisting predominantly of branched-chain paraln hydrocarbons withdrawn through lines 4I and 42 are sent to storage by means of valves 50 and 5I and lines 52 and 53, respectively, valves 54 and 55 being closed. By thus keeping the desired products separated into relatively light and relatively heavy fractions, their use as blending constituents for motor fuels is facilitated and stabilization if necessary can be carried out only on the light product. However, by closing valve 5I and opening valve 55. the entire product .can be withdrawn in a singlev stream through `line 52.

'I'he overhead passing through line 43 consists of excess hydrogen, propane, isobutane and some .possibly normal butane andl is preferably recycled to line 20 through valve B6, line 51, pump 58 and valve 59 to inhibit the conversion of the feed-into such gases and reduce the quantity which must be introduced from outside the system. During this procedure, of course, valves 61 and valve 6| for recycling as described consists essentially of propane and hydrogen. The C4 fraction is withdrawn from the bottom of tower 66 through line 68 and consists predominantly of isobutane, a large proportion of the normal butane charged through pump |1 being converted to isobutane in the process and the remainder being formed from the liquid feed.

|02 simultaneously through valves |03 and |04 and lines |05 and |06 respectively. Similarly light paraiiinic gas, catalyst slurry and activator are supplied to reaction vessels |0| and |02 by means of pump |01 and lines |08 and |09, pump ||0 and lines andV ||2, and pump ||3 and lines ||4 and ||5, respectively. Hydrogen in exp cess is supplied under the desired reaction pres- 'In another type of operation which'is advanl tageous if it is desired toobtain a product having on the average a larger number of side chains and therefore a higher antiknock value, valve 39 is opened during the early stages of a run so that mo'st of the reaction products are recycled through lines 40 and 45, pump 46 and line 41. The branched-chain paraflins upon passingagain -through the system tend to` become more branched in configuration and consequently have a still higher antiknock value. More and more of theproducts flowing through line 36 are then allowed to pass through valve 31 to the fractionating tower 38 in which these branched-chain vhydrocarbons are recovered as described above, a certain percentage ofthe total products, however, continuing to return through valve 39 to the reaction chamber I4.

Another method of accomplishing substan- -sure directly to reaction vessels |0| and |02 through inlets ||6 and ||1 respectively, these vessels being of the same type as vessel |2 in Figure 1 but shown more diagrammatically for the sake of simplicity.

The reaction in reaction chamber |0| is carried out as described above and the products passed through coolerl ||8 to separator l| I9 from which the separated catalyst complex is withdrawn and either removed from the system through valve |20 or recycled through valve |2|, line |22, pump |23 and line |24 into lines and |05 and reaction vessel |0|. The hydrocarbons and hydrogen are withdrawn from the top of separator |0| through line |25 and pass 'through valve |26 into fractionating tower |21 in which separation into desired products, heavy are withdrawn from the tower bottom through line |28 and recycled to line |05 by means-of tially the same result consists in opening valve 54 rather than valve 36 and recycling the relatively heavy sidestream product withdrawn from fractionating tower 38 through line 4| and it may even be desirable in the early stages to recycle the products withdrawn from tower 36 through line 42 by opening valv'e 55. As 'in the previous method, however, flow through valve 54 is gradually restricted so that only a desired proportion of the products is recycled.

Still another method of operation which is applicable when isobutane is desired as a principal product is to close valve entirely and recycle-the entire heavy liquid product to be broken down into isobutane, which action can be facilitated by using relatively largev amounts of catalyst and introducing little or no butane or isobutane into the system through pump |1 and line 20. By closing valve 5| and opening val've 55, the light liquidproduct can be similarly recycled. In this method of operation valves 56 and 62 are, of course, kept closed and valves l60 and 6| leading to the isobutane recovery system are operi.

Figure 2 illustrates a particularly advantageous embodiment. of our invention in which the conversion of straight-chain to branched-chain'parans is carried 'out in two steps, the reaction zone in one step being maintained at our prefferred high temperatures and pressures while in the other milder conditions, e. g. 10U-300 F. are maintained. In this way the catalyst complex formed in the low temperature stage which has lost its activity under the conditions in that stage can be used at our preferred higher temperatures to convert further quantities of straight-chain line |29, pump |30 and line |3|, while the gaseous overhead is recycled to line |08 through line |32, valve |33, line |34 and pump |35. Optionally,

, of course, any portion of the heavy materials can be eliminated through valve |16 and line |11. Finally, the products are withdrawn as sidestream through lines |36 and |31, valves |38 and |39, and lines |40 and |4|.

Reaction vessel |02 is maintained at a temperature of about 1D0-300 F. and under these conditions the formation of. gaseous hydrocarbons from the liquid feed is less .pronounced but the activity of the catalyst is not as well maintained as in -reaction vessel |0|. The total products from reaction vessel |02 pass through cooler |42, are separated from the catalyst complex in separator v|43 and pass through line |44 and valve .|45 to fractionating tower |46, the complex from separator |43 being passed through line |41, valve |48, and line |49 into line |22 for use in reaction vessel |0|. Optionally a portion of the catalyst complex in line |41 can be recycled to reaction vessel |02 through valve |50, pump 5| and line |52, but when 'its activity has reached a point at which-it is relatively inactive at -300 F. it is advantageous to restrict the amount recycled within the same stage through valve |50. As the run proceeds the flow of fresh catalyst through line to reaction vessel |0| can be gradually restricted and in some cases can be completely stopped by manipulation of valve |53, so that the activity of the catalyst is exhausted at the high temperature. used in one stage, while a part of the total feed is processed under mild conditions less conducive to gas formation.

The desired branched-chain parafiln products are removed as sidestreams from fractionating tower |46 and passed through lines |40 and |4| in which they are mixed with the light and heavy products from the first stage. The heavy liquids collecting in the bottom of tower |46, which may be for example largely'unreacted feed when the feed stock is chosen so that it boils above 235 F., is introduced into line |28 for introduction through line |25,

A y 2,266,012 into the first stage by means of line |54. Similarly, ythe gases containing less than 5 carbon atoms per molecule pass through line |55 and valve |56 into line |34 for recirculation.

In this method Vof operation valve |51 in line |58 and valve |59 in line |60 are kept closed. Vent valves |61 and |62 are also normally closed, but may be partially opened from time to ltime to allow some of the gases passing overhead from fractionating towers |21 and |46 respectively to escape from the system in order to prevent the concentration of permanent gases such as methane and ethane from building up.

Valves |63, |64 and |65 in lines |66, |61 and |68 leading to a gas fractionating system are also closed unless it is desired to obtain a fraction containing largely isobutane as one of the products. If this fraction is desired, valves |63, |64 and |65 are opened and valves-|33 and |56 closed, so that the gases from both fractionating towers |21 and |46 are combined and passed through cooler |69 and pump |10 to fractionating tower |1|, in which the hydrocarbons containing four carbon atoms per molecule are separated from the lighter gases as a liquid fraction, which consists largely of isobutane and is withdrawn from the system through line |12. The overhead, which consists largely of propane and hydrogen, is then recycled through line |68, valve |65, line |34, and pump |35, or a portion may be vented through valve |13 to prevent accumulation of undesirable permanent gases in the system. Optionally overhead from either tower |21or tower |46 may be sent to tower |1| for isobutane recovery while overhead from the other is recycled directly.

In another modification of our invention we use the second stage operating at relatively low temperatures for the purpose of increasing the average. number of side chains per molecule in the product and this can be accomplished by closing valves |04, |26, |14, and passing the entire hydrocarbon together with hydrogen from separator I9 valve |51, lines |58 and |60, and pump |15, and to line |06 for introduction into reaction vessel |02. In this way the already branched-chain parains formed in reaction vessel are subjected to further treatment to increase the degree of branching but under such mild conditions that degradation to gaseous hydrocarbons is minimized.

In still another method of accomplishing this result. valve |51 is closed and valves |26, |33, |39, |59 and |14 are opened so that fractionating tower |21 is' again operated and the heavier branched-chain products in line |36 are passed through valve |59, line |60, and pump |15 into line |06 for introduction into the second stage of th process.' The last two methods of course include the use of the catalyst complex from the separator |43 of the low temperature stage as all or a part of the catalyst required for the higher temperature conversion in reaction vessel |0l, and'other features mentioned in connection with the detailed description of Figure 2;

It is apparent that we have described a method of producing branched-chain paraffin hydrocarbons from straight-chain paraffin hydrocarbons with excellent yields and using a minimum of catalyst. In the following table the results of two runs are given which were made in glass-` lined apparatus using pure normal heptane in the presence. of an` excess of hydrogen. Run A illustrates the results obtainable according to -our invention while run B showsthat in the ab- |33, |38, |39, |59 and mixture sence of propane and the butanes, large amounts of propane andisobutane are produced from the normal heptane rather than the more valuable branched-chain parains having iive or more 5 carbon atoms per molecule.

Run No.

Charge:

N-heptane. grams-- 68. 4 68. 4 Propane. fin 18. l Isobutanem. dn l5. 5

dn 0.63 1. 0 .0 10. 0 400 3, 275 8.0 73 Mols converted per mol AlCla 66 Analysis of converted products:

P ropane and lighter -percent.. 29. 0 Isnhnmne n 3. 1 30. G C5 frnntinn dn 8.9 11. 8 Ca fraction -g -do- 17. 3 4. 3 C1 fraction dn 70. 7 2l. 2 Lost to catalyst complex do 2. 9

Runs A and B are not strictly comparable linasmuch as the total percentages converted diier considerably, and the conversion was slightly high in run B for the economical production of normally liquid branched-chain parains. Nevertheless the suppressionof the degradation of propane and isobutane is clearly shown. Run B also illustrates the formation of isobutane from normal heptane althoughnn this instance the formation of propane was not inhibited.

Many modifications of our invention and of the apparatus shown herein for carrying out the same will be apparent to those skilled in the art, and they will be able to supply numerous details not illustrated in the drawings, such as heat exchangers, provisions for Afractionating tower control, etc. We do notl desire to be limitedto the specific modifications and examples used in illustrating our invention, but only by the scope of the'appended claims.

We claim:

' 1. The process of converting a substantial portion of the straight-chain parain hydrocarbons in a substantially saturated normally liquid hydrocarbon fraction to branched-chain parafdn admixture of said hydrocarbon fraction, an aluminum halide catalyst eiective in causing said conversion, an activator for said catalyst, free hydrogen and a parainic gas containing a substantial amount of propane in a reaction zone l maintained at atemperaturein the range from about 300 F. to about 550 F. and a pressure in the range from about 500 to about 6000 pounds per square inch, said propane being present in said reaction zone :in an amount lying in the range from about 10% to about 35% by weight based on the straight-chain paraflin hydrocarbons present. 2. 'Ihe process of claim 1 wherein said temperature livesin the rangejrom about 350 F. to about 475 F. `1

3. The process of claim 1 wherein the amount aluminum chloride and aluminum bromide and said activator is a compound affording a hydrogen halide 'under the reaction conditions.

liquid-,to gaseous hydrocarbons bythe addedhydrocarbons which comprises vcontacting an y 5. 'I'he process of converting a substantial pory tion of the straight-chain' paraiiin hydrocarbons in a substantially saturated normally liquid hy-A drocarbon fraction to branched-chain parafiin hydrocarbons which comprises contacting an admixture of said hydrocarbon fraction, an aluminum halide catalyst effective in causing said conversion, an activator for said catalyst, free hydrogen and a parainic-gas consisting predominantly of propane and at least one of the butanes in a reaction zone maintained at a temperature in the range from about 300 F. to about 550 F. and a pressure in the range from about 500 to about 6000 pounds per square inch, saidpropane being present in said reaction zone in an`amount lying in the range from about 10% to about 35% by weight and said butane being present in an amount lying in the range from 'about 5% to about 25% by weight based on the straight-chain vparaiiln hydrocarbons present.

propane and at least one of the butanes in a` reaction zone maintained at a temperature in the range from about 300 F. to about 550 F. and a pressure in the range from about 500`to about 6000 pounds per square inch whereby not more than 65% to 70% of said straight-chain paraftln hydrocarbons undergoes reaction per pass through said reaction zone, said propane being present in said reaction zone in an amount lying in the range from about 10% to about 35% by weight and said butane being present in an amount lying in -the range from` about to about 25% by weight based on the straight-chain paraiiin hydrocarbons present, withdrawing the products from said reaction zone, separating said products into a catalyst-containing portion and a hydrocarbon portion, returning at least a part of said catalyst-containing portion to said reaction zone, separating said hydrocarbon portion into a relatively heavy liquid fraction, a relatively light liquid fraction and a normally gaseous fraction, and returning at least a portion of said relatively heavy liquid fraction and said gaseous fraction to said reaction zone.

9. The process of preparing isobutane from normal butane and a substantially saturated hy drocarbon naphtha rich in straight-chain paraiiin hydrocarbons which comprises contacting an admixture of said hydrocarbon naphtha, normal butane, an aluminum halide catalyst effective in converting straight-chain to branchedchain parailin hydrocarbons, an activator for said catalyst, free hydrogen and propane in a reaction zone' maintained at a temperature in the range from about 300 F. to about 550 F. and a pressure in the range from about 500 to about 6000 pounds per square inch, said propane being present in said reaction zone in an amount lying in the range from about 10% to about 35% by weight based on the straight-chain paraflin hydrocarbons present.

10. The process of preparing isobutane from a substantially saturated hydrocabon naphtha rich in straight-chain paramn hydrocarbons which comprises contacting an admixture oi said hydroabout 25% by weight based on the straight-chain paraffin hydrocarbons present, withdrawing the products from said reaction zone, separating said products into a catalyst-containing portion, a liquid fraction containing hydrocarbons having at least iive carbon atoms per molecule and a gaseous fraction containing hydrocarbons with less than iive carbons per molecule. and returning at least a major portion of saidgaseous fraction to said reaction zone.

'7. The process of claim 6 including the step of returning at least a part of said catalyst-containing portion to said reaction zone.

8. The process of preparing liquid branchedchain paraiiin hydrocarbons from a substantially saturated hydrocarbon fraction rich in straightchain parain hydrocarbons and boiling within the range from about 100 F. to about 500 F. which comprises contacting an admixture oi' said hydrocarbon fraction, an aluminum halide .catalyst eiective in converting straight-chain to branched-chain parafiin hydrocarbons, an activator for said catalyst, free hydrogen and a parainic gas containing substantial amounts oi' propane and at least one of the butanes in a reaction zone maintained at a temperature in the range from about 300 F. to about 550 F. and a pressure in the range from about 500 to .about 6000 pounds per square inch, said propane being present in said reaction zone in an amount lying in the range from about 10% to about 35% by weight and said butane being present in an amount lying in the range from about 5% to carbon naphtha, an aluminum halide catalyst efiective in converting straight-chain to branchedchain paramn hydrocarbons, an activator for said catalyst, free hydrogen and propane in a reaction zone maintained at a temperature in the Arange from about 300 F. to about 550 F. and a pressure in the range from about 500 to about 6000 pounds per square inch, said propane being present in said 'reaction zone in an amount lying in the range from about 10% to about 35% by weight based on the straight-chain paraiiin hydrocarbons present, removing the products irom said reaction zone, separating a normally gaseous fraction from said products, further separating said normally gaseous fraction into a relatively heavy fraction consisting predominantly of hydrocarbons having four carbons per molecule and containing a large proportion of isobutane and a relatively light fraction containing propane, and returning at least a part of said relatively light fraction to said reaction zone.

11. The process oi' preparing liquid branchedchain paraiiin hydrocarbons and isobutane from a substantially saturated hydrocarbon naphtha. rich in liquid straight-chain paraiiin hydrocarbons which comprises contacting an admixture oi' -said hydrocarbon naphtha, an aluminum halide catalyst eii'ective in converting straightchain to branched-chain paraffin hydrocarbons, an activator for said catalyst, i'ree hydrogen and propane in a reaction zone maintainedl at a temperature in the range from about 300 F. to about 550 F. and a pressure in the range from about 500 to about 6000 pounds per square inch, said propane being present in said reaction zone in an amount lying in the range from about 10% to about 35% by weight based on the straight-chain paraiiin hydrocarbons present, removing the products from saidreaction zone, separating said products into a catalyst-containing portion, a normally liquid fraction and a normally gaseous traction, further separating said gaseous fraction ,liquid hydrocarbon fraction, an aluminum halide catalyst eiective in causing said conversion, an activator for said catalyst, free hydrogen and a paraiiinic gas containing a substantial amount of propane in a first reaction zone maintained at a temperature in the range from about 300 F. to about 550 F. and a pressure in the range from about 500 to about 6000 pounds per square inch, said propane being present in an amount lying in the range from about 10% to aboutJ 35% by Weight based on. the straight-chain paraiin hydrocarbons present, removing the products trom said rst reaction zone, contacting an admixture of a second substantially saturated normally liquid hydrocarbon fraction and further quantities of said catalyst, said activator and free hydrogen in a second reaction zone maintained at a temperature in the range from about 100 F. to about 300 F., separating the products from said second reaction zone into a catalyst-containing portion and a hydrocarbon portion, and introducing at least a part of said catalyst-containing portion into said rstrreaction zone.

13, The process of converting a substantial portion of the straight-chain parafn hydrocarbons in a substantially saturated normally' liquid hydrocarbon fraction to branched-chain paraiin hydrocarbons which comprises contact# ing an admixture of a substantially saturated normally liquid hydrocarbon fraction, an aluminum halide catalyst effective in causing said conversion, an activator for said catalyst, free hydrogen and a parainic gas containing a substantial amount of propane in a rst reaction zone maintained at a temperature in the range from about 300 F. to about 550 F. and a pressure in the range from about 500 to about 6000 pounds per square inch, said propane being present in an amount lying in the range from about 10% to about by weight based on'the straight-chain parain hydrocarbons present, removing the products from said rst reaction zone, separating said products into a catalyst-containing portion and a hydrocarbon portion, contacting an admixture of at least a part of said hydrocarbon portion and further quantities of said catalyst, said activator and free hydrogen in a second reaction zone maintained at a temperature in the range from about F. to about l300 F., removing the products from said second reaction zone and recovering branched-chain paran hydrocarbons from said last-mentioned products.

i4. The process of claim 13 wherein said paranic gas contains an amount of at least one of the butanes lying in the range from about 5% to about 25% by weight based on the straightchain paraiin hydrocarbons present.

EDMoND L. nioUVImE. BERNARD L. EVERING. 

